초록 ▼

A layered heater is provided that comprises at least one resistive layer defining a circuit configuration, the circuit configuration comprising at least one resistive trace oriented relative to a heating target and comprising a material having temperature coefficient characteristics such that the re

A layered heater is provided that comprises at least one resistive layer defining a circuit configuration, the circuit configuration comprising at least one resistive trace oriented relative to a heating target and comprising a material having temperature coefficient characteristics such that the resistive trace provides power commensurate with demands of the heating target. In one form, resistive traces of the resistive layer are a PTC material having a relatively high TCR and are oriented approximately perpendicular to a primary heating direction. In another form, resistive traces of the resistive layer are an NTC material having a relatively high BETA coefficient and are oriented approximately parallel to a primary heating direction.

대표청구항 ▼

1. A constant voltage heater system comprising: a heating target defining a primary heating direction along which a heating target power gradient occurs; anda layered heater disposed proximate the heating target, the layered heater comprising: at least one dielectric layer;at least one resistive lay

1. A constant voltage heater system comprising: a heating target defining a primary heating direction along which a heating target power gradient occurs; anda layered heater disposed proximate the heating target, the layered heater comprising: at least one dielectric layer;at least one resistive layer formed on the dielectric layer and defining a single combination of: a parallel circuit, the parallel circuit comprising a plurality of resistive traces;the resistive traces comprising a positive temperature coefficient material having a relatively high TCR; andthe resistive traces being oriented approximately perpendicular to the primary heating direction; andat least one protective layer formed on the resistive layer,wherein the resistive traces are responsive to the heating target power gradient such that the resistive traces output additional power proximate a higher heat sink and less power proximate a lower heat sink along the primary heating direction. 2. The heater system according to claim 1, wherein the layered heater is applied directly to the heating target. 3. The heater system according to claim 1 further comprising a substrate disposed proximate the heating target, wherein the layered heater is applied to the substrate. 4. A heater system comprising: a heating target defining at least a first heating direction along which a first heating target power gradient occurs and at least a second heating direction along which a second heating target power gradient occurs; anda layered heater disposed proximate the heating target, the layered heater comprising:a first conductive layer comprising a terminal tab;a continuous resistive layer applied on the first conductive layer, the continuous resistive layer comprising a positive temperature coefficient material having a relatively high TCR, the continuous resistive layer substantially covering the first conductive layer, the continuous resistive layer having a resistance over its entire area;a second conductive layer applied on the continuous resistive layer, the second conductive layer comprising a terminal tab; anda dielectric layer applied on the second conductive layer,wherein the layered heater is responsive to the first and second heating target power gradients such that the continuous resistive layer outputs additional power proximate a higher heat sink and less power proximate a lower heat sink along the first and second heating directions, and the terminal tabs provide for the application of power to the heater system, the terminal tabs being connected in parallel such that power is applied to the entire heater system. 5. A constant voltage layered heater comprising: at least one dielectric layer;at least one resistive layer formed on the dielectric layer and defining a single combination of: a circuit configuration, the circuit configuration comprising at least one resistive trace,the resistive trace oriented relative to a heating target, andthe resistive trace comprising a material having temperature coefficient characteristics such that the resistive trace provides power commensurate with demands of the heating target; anda protective layer formed on the resistive layer. 6. A constant voltage heater system comprising: a hot runner nozzle defining a longitudinal axis extending between a manifold end and a tip end of the hot runner nozzle; anda layered heater disposed proximate the hot runner nozzle, the layered heater comprising: at least one resistive layer defining a single combination of: a parallel circuit, the parallel circuit comprising a plurality of resistive traces,the resistive traces comprising a positive temperature coefficient material having a relatively high TCR, andthe resistive traces being oriented approximately perpendicular to the longitudinal axis of the hot runner nozzle; andat least one protective layer formed over the resistive layer,wherein the resistive traces are responsive to a heating target power gradient extending between the manifold end and the tip end such that the resistive traces output additional power proximate the manifold end and the tip end and less power between the manifold end and the tip end. 7. A constant voltage heater system comprising: a hot runner nozzle defining a longitudinal axis extending between a manifold end and a tip end of the hot runner nozzle; anda layered heater disposed proximate the hot runner nozzle, the layered heater comprising at least one resistive layer and a protective layer formed over the resistive layer, the resistive layer defining: a plurality of resistive trace zones, each resistive trace zone comprising a different watt density than an adjacent resistive trace zone; anda plurality of resistive traces within the resistive trace zones, the resistive traces defining a single combination of: a parallel circuit,a positive temperature coefficient material having a relatively high TCR, andthe resistive traces being oriented approximately perpendicular to the longitudinal axis of the hot runner nozzle,wherein the resistive layer is responsive to a heating target power gradient extending between the manifold end and the tip end such that the resistive layer outputs additional power proximate the manifold end and the tip end and less power between the manifold end and the tip end. 8. A constant voltage layered heater for use proximate a heating target, the heating target defining a primary heating direction along which a heating target power gradient occurs, the layered heater comprising: a dielectric layer;a resistive layer formed on the dielectric layer, the resistive layer defining: a plurality of resistive trace zones, each resistive trace zone comprising a different watt density than an adjacent resistive trace zone; anda plurality of resistive traces within the resistive trace zones, the resistive traces defining a single combination of: a parallel circuit,a positive temperature coefficient material having a relatively high TCR, andthe resistive traces being oriented approximately perpendicular to the primary heating direction; anda protective layer formed over the plurality of resistive traces,wherein the resistive traces are responsive to the heating target power gradient such that the resistive traces output additional power proximate a higher heat sink and less power proximate a lower heat sink along the primary heating direction. 9. A constant voltage layered heater for use proximate a heating target, the heating target defining a primary heating direction along which a heating target power gradient occurs, the layered heater comprising: at least one dielectric layer;at least one resistive layer formed on the dielectric layer and defining a single combination of: a parallel circuit, the parallel circuit comprising a plurality of resistive traces,the resistive traces comprising a positive temperature coefficient material having a relatively high TCR, andthe resistive traces being oriented approximately perpendicular to the primary heating direction of the heating target; andat least one protective layer formed on the resistive layer,wherein the resistive traces are responsive to the heating target power gradient such that the resistive traces output additional power proximate a higher heat sink and less power proximate a lower heat sink along the primary heating direction. 10. A layered heater for use proximate a heating target, the heating target defining at least a first heating direction along which a first heating target power gradient occurs and at least a second heating direction along which a second heating target power gradient occurs, the layered heater comprising: a first conductive layer comprising a terminal tab;a continuous resistive layer applied on the first conductive layer, the continuous resistive layer comprising a positive temperature coefficient material having a relatively high TCR, the continuous resistive layer substantially covering the first conductive layer, the continuous resistive layer having a resistance over its entire area;a second conductive layer applied on the resistive layer, the second conductive layer comprising a terminal tab; anda dielectric layer applied on the second conductive layer,wherein the layered heater is responsive to the first and second heating target power gradients such that the continuous resistive layer outputs additional power proximate a higher heat sink and less power proximate a lower heat sink along the first and second heating directions, and the terminal tabs provide for the application of power to the layered heater, the terminal tabs being connected in parallel such that power is applied to the entire layered heater. 11. A method of heating a heating target, the method comprising the step of energizing a constant voltage layered heater comprising at least one dielectric layer, at least one resistive layer formed on the dielectric layer and defining single combination of: a circuit configuration, wherein the circuit configuration comprises at least one resistive trace,the resistive trace oriented relative to the heating target, andthe resistive trace comprising a material having temperature coefficient characteristics such that the resistive trace provides power commensurate with demands of the heating target, anda protective layer formed over the resistive layer, wherein the dielectric layer provides electrical isolation and the protective layer provides insulation during the heating of the heating target.